General purpose packing material



Aug. 8, 9 7 J. M. PEZELY, JR.. ETAL 3,334,798

GENERAL FURPOSE PACKING MATERIAL Filed March 2, 1965 2 Sheets-$heet l 'lM I NVENTORS JOSEPH M. PEZELY, JR. y VICTOR SCHLEICH M TM, s v

ATTORNEYS 8, 1957 J. M. PEZELY, JR., ETAL 3,334,798

GENERAL PURPOSE PACKING MATERIAL Filed March 2, 1965 2 Sheets-Sheet 2INVENTOR5 JOSEPH M. PEZELY,JR. BY VICTOR SCHLEICH zm,m ZM M ATTORNEYUnited States Patent 3,334,798 GENERAL PURPOSE PACKING MATERIAL JosephM. Pezely, Jr., Elmira, N.Y., and Victor Schleich, Wiiliamsport, Pa.,assignors to Corning Glass Works,

Corning, N.Y., a corporation of New York Filed Mar. 2, 1965, Ser. No.436,599 2 Claims. (Cl. 229-14 ABSTRACT OF THE DISCLOSURE Packagingmodules of impact absorbing material having interlocking tongue andgroove portions are provided for side, edge, and corner protectivepositionment about an article to be packaged.

Quite commonly fragile articles that are packed within outer boxes orcontainers are spaced from the walls of the outer container andcushioned from shock or impact by shock absorbing material, such aswaste paper, excelsior, foam rubber, foam plastic, etc. The shockabsorbing material may be in the form of individually constructedpieces, such as sheets, edge protecting channels, corner pads, specialpads and combinations of these such as a sheet with an angle on an edge.

Such shock absorbing packing pieces are placed on appropriate edges,corners, sides, etc. of a fragile item to be shipped which is thenplaced within an outer corrugated boxor shipping carton for shipment.

Different individual fragile items and difierent sized shipping cartonsmake it extremely difiicult to stock and inventory suflicient packingpads of all difierent types at a reasonable cost.

The cost of the packaging pads or materials is escalated upwardly byseveral factors. First, the cost of making the different packaging padsor materials is increased by the use of expensive molding processes.Molding is particularly necessary for odd shaped corner and edge pieces.Secondly, the cost to the shipper of keeping many pieces of difierentsizes and shapes in inventory is excessive. This invention provides asolution to the problem through modular packing pieces which may be allidentical but which can be assembled in the nature of a jigsaw puzzle toprovide a number of required different shapes of packing pads.

It is the purpose of this invention to provide packaging pads assembledfrom modules which, because of their particular construction, areextremely versatile. The modules are so constructed and arranged thatthey may be combined with other identical modules to form packaging padsof various sizes and shapes.

For example, the modules can be assembled into sheets, edge protectingchannels, edge protecting angles, corner pads and combinations of thesesuch as a sheet with an angle on one side, and a corner at the end ofthe angle.

Each module has a unique relationship between its thickness and the sizeof the tongues and grooves which are employed for joining the modulestogether. The position of the tongues and the grooves on the edges ofthe module is also important. Each module has a specific relationship ofone-to-one between the thickness of the module itself, and the length,width or depth of the tongue or groove. The tongues and the grooves areso positioned along the side of the module that the tongue of one modulemay be inserted into a groove of another identical module in a directioneither parallel to or perpendicular to the planes of the parallel sidesof the module so that the resulting pad will be either a sheet or aright angle piece respectively, wherein the modules form a neat alignedpackaging pad of the desired shape.

3,334,798 Patented Aug. 8, 1967 Other objects and advantages of theinvention will be pointed out in the following description and claimsand illustrated in the accompanying drawings, which disclose, by way ofexample, the principles of the invention and the best mode which hasbeen contemplated of applying these principles.

In the drawings:

FIGURE 1 is a perspective view showing one embodiment of the invention.

FIGURES la through 1d show various applications of the embodiment shownin FIGURE 1.

FIGURE 1a is a plan view of a sheet formed by four modules of theembodiment shown in FIGURE 1.

FIGURE 1b illustrates a corner piece formed by three modules of theembodiment in FIGURE 1.

FIGURES 1c and 1d show edge-protecting pads formed by combinations ofthe module shown in FIGURE 1.

FIGURE 2 is a perspective view showing a modification of the embodimentshown in FIGURE 1.

FIGURE 3 is a perspective view showing another embodiment of theinvention.

FIGURE 4 is a perspective view showing a modification of the embodimentshown in FIGURE 3.

FIGURE 4a shows a sheet formed from modules of the modification shown inFIGURE 4.

FIGURE 5 shows a shipping container carrying a fragile article protectedby packaging pads constructed from modules in accordance with thisinvention.

FIGURE 1 shows a preferred embodiment of the versatile module. Themodule A is formed of shock absorbing material and has two parallel flatsides 1. Four flat edges, '2, 3, 4 and 5, lie in planes perpendicular tothe planes of the parallel flat sides 1. Extending from the edge 3 is atongue 6. The size of the tongue 6 is determined by its length 7, itswidth 8 and its thickness 9. In order that the various shaped packagingpads may be formed from this versatile module, it is important thatlength 7 be equal to width 8 and thickness 9. Further, the thickness 9of the tongue should be equal to the distance between the flat sides 1of the module.

A groove 13 in the side 4 is formed of dimensions which are identical tothose of the tongue 6. Thus, depth 10 of the groove 13 equals the length7 of the tongue, width 11 of the groove equals the width 8 of thetongue, and thickness 12 of the groove equals the thickness 9 of thetongue.

The universal nature of the module shown in FIG- thickness of the module1: edge portion 3a, tongue length 7, tongue width 8, edge portion 3b,edge portion 3c, edge portion 4a, edge portion 412, groove depth 10 andgroove width 11;

FIGURES la through 1d illustrate the manner in which the module may becombined with other similar modules to provide packaging pads of varioussizes and shapes. FIGURE 1a is a plan view of a sheet 14 formed by fourof the modules illustrated in FIGURE 1. The tongue 6 of upper lefthandmodule 15 is shown projecting into the groove of next adjacent,identical module 16. The groove 13 in the module 15 is shown receivingthe tongue of the next adjacent, identical module 17.

FIGURE 1b shows a corner protecting pad formed by three of the modulesshown in FIGURE 1. In this arrangement the tongue of module 18 projectsdownward into the groove of module 19. The tongue of module 19 thenprojects into the groove of module 30.

3 The tongue of module 30 then projects into the groove of the module18.

The edge protecting pad shown in FIGURE is formed by turning the modulesand 16 of FIGURE 1a 90 degrees out of the plane of the drawing. FIGURE1d shows an edge protecting pad formed by only the two modules 15 and 17of FIGURE la.

FIGURE 2 shows a modification of the embodiment shown in FIGURE 1. Theline 1a indicates the plane of the second flat side opposite the firstflat side 1. The relationships of the tongue and groove dimensions tothe distance between the fiat sides 1 and 1a are identical to thosebetween the tongue and groove dimensions of the module shown in FIGURE 1to the distance between the fiat sides 1. It follows then that themodule of FIG- URE 2 can be combined to form packaging pads of varioussizes and shapes substantially similar to those described above usingthe module of FIGURE 1.

' The module of FIGURE 2, however, is provided with portions 35 whichside 1a and separated by indentations 36. These raised portions areintended to enhance the shock absorbing characteristics of the pad. Whena shock is imparted to the module in a direction perpendicular to theplane of the flat sides, the raised portions 35 and the indentations 36will allow the module to yield to a certain extent. This movement willtend to spread the shock out upon the item being shipped.

In forming packaging pads from this module the raised portions 35 willnormally be placed on the side of the pad away from the object beingprotected. If, however, it is desired to place the raised portions onthe side of the pad adjacent the fragile objects the corners of the padmay be pushed together neatly by force fitting the modules together.

The module shown in FIGURE 21 molding process.

FIGURES 3 and 4 illustrate another embodiment of the invention. Althoughthe primary purpose of this embodiment is to form a packaging sheet, itis apparent that the module of this embodiment can also be combined withother identical modules or with the module of FIG- URE l to formpackaging pads of various sizes and shapes. For example, they may form aright-angle piece similar to that shown in FIGURES 10 or 1d, or they mayform an angle piece, one side of which extends outwardly to form apackaging sheet of indeterminate length. Other obvious combinations areclearly within the scope of this invention.

For a module to be used along with other identical modulesto form asheet of indeterminate size, it is important that the module be in theform of a regular polygon having an even number of sides whereinopposite sides of the polygon are complementary. Thus, in the embodimentshown in FIGURE 3, top edge is complementary to bottom edge 25'. Edgeportion 20 equals edge portion 20'. Depth 21 of the groove 26 equalslength 21 of the tongue 27. Similarly, width 22 of the groove equalswidth 22' of the tongue, depth 23 of the groove equals length 23 of thetongue. And finally, edge portion 24 equals edge portion 24. Similarly,the edge 28 is complementary to the edge 29.

In the embodiment of FIGURE 3, as in the embodiment of FIGURE 1, thedimensions of the tonguethat is, the length, the width and thethicknessand the dimensions of the groove-that is, the depth, the widthand the thickness-are all equal to each other and equal to the thicknessof the module itself. This relationship allows the module shown inFIGURE 3 to be combined with other modules to form packaging pads ofvarious sizes and shapes. For example, with two rows of modules of thetype shown in FIGURE 3, each row being of indefinite length, an edgeprotecting piece similar to that shown in FIGURES 1c and id, but ofindefinite length, can be formed. In addition, one of the rows can be 2would be made by are raised from the plane of flatextended sideways,thus providing a sheet with an edge angle. Further, one of therows canbe joined at a rightangle to a third row to form a packaging pad havinga U-shaped or a Z-shaped cross-section. The U-shaped pad can be closedoil on the fourth side and/ or at either end or both ends to form arectangular channel, an open box or a closed box respectively. It isapparent that in any one of the above packaging pads the sides may be ofany area, depending only on the number of modules used to form the side.

It is also apparent that the above examples are intended merely toillustrate some of the almost infinite possible packaging pads that maybe formed fromthe module of this embodiment, and in no way are theyintended to be a limitation on its application.

The modification of FIGURES 4 and 4a illustrate that any regular polygonhaving an even number of sides may becombined to form a packaging sheet.In FIG- URES 4 and 4a, a six-sided polygon is shown. Consistent with thebasic concept of this invention, it would only be necessary that theopposite sides of the polygon be complementary..Thus, as shown in FIGURE4, edge .31 would be equal to edge 31', tongue 32 would fit into groove32', and edge portion 33 would equal edge portion 33..

As in the embodiment shown in FIGURE 3, the modification of FIGURES 4and 411 may be combined to form packaging pads of an almost infinitenumber of sizes and shapes. For example, tongues 43 and 44 of modules 41and 42 lying along line 40, mayboth be joined at a ninety degree anglewith other similar modules to form an edge protecting piece similar tothat shown in FIGURES 1c or 1d. This pad is then capable of being.

extended to form pads of the same sizes and shapes discussed above withrespect to the embodiment of FIG- URE 3. And, similarly, the possiblevariations are almost infinite.

The possibility of employing the instant invention in a module of morethan four sides is important and extremely useful. In the event that twounattached objects are placed side by side, for shipping or handling, onone packaging sheet, it would be preferred that the space.

between the objects not lie in a plane coincident to the plane of a linejoining any two rows of the packaging sheet. In shipping or handling,one of the two objects may slip with respect to the other. If the planealong which they slip is coincident with a plane joining a row ofmodules, the packaging sheet may separate at that plane. This may beavoided, however, by choosing the module with the appropriate number ofsides.

For example, if two objects placed on the sheet of FIGURE 4a met alongline 45 or any line parallel thereto, the possibility of the joiningedge of the two objects running coincident with a joining edge of tworows of modules would be eliminated by using a six sided module.

Similarly, for two objects joined on zig-zag line 46, the four sidedmodule of FIGURE 3 would be employed to avoid pad separation.

FIGURE 5 shows a fragile article being carried in a container 50 andprotected against damage by several shock absorbing pads formed bymodules of the instant invention. Pad 51, protecting a lower corner, isidentical to the pad shown in FIGURE lb. Pad 52, which is protecting thetop and an upper edge of the fragile article, is formed by a series ofmodules of the embodiment shown in FIGURE 3. A row of modules 54,adjacent edge 53 of the fragile article, is joined at a ninety degreeangle with the flat portion of the pad 52. In this manner a pad 52 isformed which protects both the top and an upper edge of the fragilearticle. A pad similar to that shown in FIGURE 10 is shown at 55protecting one side of the fragile article.

For several reasons, the packaging module provided by this inventionwill enable packaging costs to be significantly reduced. First, theversatility of the module will allow one confronted with many variedpackaging problems to keep in stock only the packaging module of theinstant invention. Most, if not all, of the packaging pads that he willneed, regardless of size or shape, can be formed by various combinationsof the module disclosed herein. Thus, he need keep in inventory only asingle size and shape module. This uniformity of parts willsignificantly reduce his inventory costs. Secondly, this module isCapable of being produced by extrusion and casting techniques. These areconsiderably cheaper than the present molding process.

The module is capable of being produced by various methods. First, themodule can be molded into the desired shape. This is not considered tobe the best method, however, since, as noted above, this method isexpensive. A second method would be by the extrusion process. Here thematerial would be extruded in the shape of the outline of the plan viewof the module and would be sliced to the desired thickness. A thirdmethod would be to employ casting. By this method, large sheets ofmaterial of the desired thickness would be cast. A cutter similar to acookie cutter would then be used to cut the sheet into modules of thedesired shape.

The material employed to form the module must have superior shockdamping characteristics and must be bulky. The bulkiness is necessarybecause of the relationship of the size of the various edge dimensionsto the thickness of the module. Accordingly, at present it appears thatexpandable polystyrene foam is the best allaround material to producethis product. Due to the need for bulkiness, the low densitycharacteristics of expandable polystyrene foam makes this materialparticularly suitable.

While there have been shown and described and pointed out thefundamental novel features of the invention as applied to the preferredembodiment, it will be understood that various omissions andsubstitutions and changes in the form and details of the deviceillustrated and in its operation may be made by those skilled in the artwithout departing from the spirit of the invention. It is the intention,therefore, to be limited only as indicated by the scope of the followingclaims,

What is claimed is:

1. In the packaging of frangible articles, a plurality of interlockingpackaging modules positioned about said frangible article to maintainthe same in spaced-apart relationshi from an enclosing container whereinthe improved packaging module construction comprises, a plurality ofidentical modular bodies of shock absorbing material, each said bodycomprising a first fiat side, a second flat side parallel to said firstflat side, and an even number of edges perpendicular to said first andsecond flat sides, said edges forming a regular polygon, each pair ofedges on opposite sides of said polygon being parallel to each other andforming a set of edges, a tongue projecting from one of said set ofedges, a groove formed in the other of said set of edges, said tongueand said groove both being cubical in shape, the edge dimension of saidcubical tongue and groove being equal to the distance between the twoflat sides; a tongue of one such module is positioned within a groove ofan adjacent module, with the groove of the adjacent module correspondingto the groove of said first module which is located on the edge oppositefrom the tongue of said first module, wherein a plurality of saidinterlocked modules are positioned about a frangible article to maintainit in spaced-apart impact relationship from an enclosing container.

2. In the packaging of frangible articles as defined in claim 1, theimprovement comprising a plurality of raised portions projectingoutwardly from said first flat side of each said packaging module, andindentation portions separating said raised portions, so as to enhancethe shock absorbing characteristics of each said packaging module.

References Cited UNITED STATES PATENTS 1,894,061 1/1933 Sanders 46-252,057,942 10/1936 Fay 46 31 3,166,227 1/ 1965 Ragnow 22914 THERON E.CONDON, Primary Examiner. WILLIAM T. DIXSON, JR., Examiner,

1. IN THE PACKAGING OF FRANGIBLE ARTICLES, A PLURALITY OF INTERLOCKING PACKAGING MODULES POSITIONED ABOUT SAID FRANGIBLE ARTICLE TO MAINTAIN THE SAME IN SPACED-APART RELATIONSHIP FROM AN ENCLOSING CONTAINER WHEREIN THE IMPROVED PACKAGING MODULE CONSTRUCTION COMPRISES, A PLURALITY OF IDENTICAL MODULAR BODIES OF SHOCK ABSORBING MATERIAL, EACH SAID BODY COMPRISING A FIRST FLAT SIDE, A SECOND FLAT SIDE PARELLEL TO SAID FIRST FLAT SIDE, AND AN EVEN NUMBER OF EDGES PERPENDICULAR TO SAID FIRST AND SECOND FLAT SIDE, SAID EDGES FORMING A REGULAR POLYGON, EACH PAIR OF EDGES ON OPPOSITE SIDES OF SAID POLYGON BEING PARALLEL TO EACH OTHER AND FORMING A SET OF EDGES, A TONGUE PROJECTING FROM ONE OF SAID OF EDGES, A GROOVE FORMED IN THE OTHER OF SAID SET OF EDGES, SAID TONGUE AND SAID GROOVE BOTH BEING CUBICAL IN SHAPE, THE EDGE DIMENSION OF SAID CUBICAL TONGUE AND GROOVE BEING EQUAL TO THE DISTANCE BETWEEN THE TWO FLAT SIDES; A TONGUE OF ONE SUCH MODULE IS POSITIONED WITHIN A GROOVE OF AN ADJACENT MODULE, WITH THE GROOVE OF THE ADJACENT MODULE CORRESPONDING TO THE GROOVE OF SAID FIRST MODULE WHICH IS LOCATED ON THE EDGE OPPOSITE FROM THE TONGUE OF SAID FIRST MODULE, WHEREIN A PLURALITY OF SAID INTERLOCKED MODULES ARE POSITIONED ABOUT A FRANGIBLE ARTICLE TO MAINTAIN IT IN SPACED-APART IMPAACT RELATIONSHIP FROM AN ENCLOSING CONTAINER. 